The Starrett HDV400-M3-2LED Horizontal Digital Video System Comparator is an advanced optical measurement system designed for high-precision dimensional inspection. It combines the traditional optical comparator’s functionality with modern digital video and software technologies to measure and analyze parts with extreme accuracy and repeatability.

Here’s a detailed technical explanation:

1. Purpose

• To perform high-precision dimensional measurements of parts by comparing them to CAD models or pre-set dimensions.
• Useful in quality control, reverse engineering, and high-accuracy inspection tasks.

2. Core Components

1. Optical System:
   • Equipped with a high-quality lens that projects an image of the part onto the digital video screen for measurement and analysis.
   • Provides a horizontal orientation for placing and inspecting parts like shafts, gears, and flat components.
2. High-Resolution Camera:
   • Captures precise digital images of the part for analysis.
   • Offers magnification levels to ensure small features and details are accurately measured.
3. LED Illumination:
   • Dual LED Light Sources:
     • Front LED (for surface illumination).
     • Rear LED (for profile illumination).
   • Ensures even and consistent lighting for accurate image capture.
4. Digital Display and Video Overlay:
   • The comparator features a high-resolution monitor displaying the live video feed.
   • Supports real-time overlay of CAD files, enabling direct comparison between the part and its design.
5. Measurement Stage:
   • A robust and precise stage that allows for smooth and controlled movement of the part.
   • Stages are motorized or manual, depending on the configuration, with micron-level precision for positioning.
6. Software System:
   • Integrated MetLogix M3 Software, designed for advanced measurement and analysis.
   • Features:
     • CAD import and overlay.
     • Automated edge detection for accurate measurements.
     • Measurement data recording and reporting.
   • Offers programmable measurement routines for repeatable tasks.
7. Frame and Build:
   • Heavy-duty construction to minimize vibrations and maintain stability during precise measurements.
   • Designed to handle parts of varying weights and sizes.

3. Working Principle

1. Part Placement:
   • The part to be inspected is placed on the measurement stage, aligning it with the optical system.
2. Image Capture:
   • The high-resolution camera captures the profile or surface image of the part using optimal illumination settings.
3. Measurement and Analysis:
   • The system overlays the part’s image with a CAD model or predefined geometry for comparison.
   • The software detects edges and calculates dimensions such as length, diameter, angles, and radii.
4. Data Output:
   • Measurement data is displayed on the screen and can be exported for documentation or further analysis.

4. Technical Features

1. Measurement Capabilities:
   • Measures dimensions such as lengths, diameters, radii, and angles with micron-level accuracy.
   • Supports both profile and surface measurements.
2. Camera Resolution:
   • High-resolution camera ensures clear image capture, even for small or intricate parts.
3. Field of View (FOV):
   • Large enough to accommodate medium-sized parts while maintaining fine detail for smaller features.
4. Illumination Control:
   • Adjustable LED lighting ensures optimal contrast for edge detection.
5. Precision Stage:
   • Allows for precise X, Y, and Z-axis movements with repeatability in the micron range.
6. Software Features:
   • Automated feature recognition.
   • CAD overlay with DXF file compatibility.
   • Statistical process control (SPC) reporting.

5. Applications

1. Aerospace and Automotive:
   • Inspection of complex geometries and tight-tolerance components like gears and shafts.
2. Medical Devices:
   • Measuring precision parts used in surgical instruments or implants.
3. Machining and Manufacturing:
   • Quality control for machined parts, ensuring compliance with design specifications.
4. Tool and Die:
   • Inspecting cutting tools, molds, and other precision components.

6. Advantages

1. Precision:
   • Offers high accuracy and repeatability, ideal for critical inspection tasks.
2. Efficiency:
   • Automates many measurement processes, reducing time and manual effort.
3. Versatility:
   • Measures a wide variety of part types and sizes, from small intricate features to larger components.
4. Digital Integration:
   • CAD compatibility streamlines comparisons and reduces human error.
5. User-Friendly:
   • Software interface simplifies programming and operation for users of varying skill levels.

7. Typical Specifications

Conclusion

The Starrett HDV400-M3-2LED is a cutting-edge digital optical comparator designed for high-precision, automated inspection tasks. Its combination of traditional optical measurement techniques with advanced digital technologies makes it a versatile and indispensable tool in modern manufacturing and quality control environments.

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